I want to build multiple car shaped beds for the familiy. I have a template for the side profile and want to know if there is a safe affective way to simply lay the template on top and use a router to cut the shape in one pass. Its 3/4” birch. I want to avoid using a jig saw and then flush trimming. This would save me an significant amount of time but what are my Options??

9 replies so far

Yeah, this one is easy, you want a pattern bit. A pattern bit is a straight bit that has a bearing on the top or bottom that rides along another piece you do not want to trim, and cuts the part above or below it. Be sure to put a little light oil on the bearing before starting. Just use a jig saw to sloppily rough cut your sides a little larger than you want. Clamp or screw your template to it, than go at it with the router to trim it. Tricky part is getting that first piece cut just right and perfect to be the pattern. One way to approach that problem is to cut as close as feasible with your jig saw, being extremely careful not to undercut anything, overcutting a little is allowable. Than use a oscillating spindle sander to sand the edges into final shape. Much easier to sand to a line on a sander than to cut to one with a jig or band saw.

Make sure you attach the pattern piece to the plywood to be cut. Screw it in areas that will be cut away or use double sided tape, or both.

If you mean that the pattern is a piece of paper, then attach the pattern to a piece of 1/2 inch plywood and cut and sand the plywood to be the correct shape and then adhear the plywood to the wood to be cut.

spot on lee I would say 4-5 passes. On the other hand with an good saber saw blade you could cut it within an 1/8” of the line and just flush trim it in 1 pass. I think the saber saw and flush trim will be faster with a cleaner end product.

Coleby, Lee is right on the money, with the how too, but if you’re looking to save time, then the jigsaw cut and flush trim is the fastest method since you can flush trim in 1 pass if you’re just cleaning up an 1/8” off the edge, and you’ll have alot less mess to as Lee points out.

-- I've decided 1 mistake is really 2 opportunities to learn.. learn how to fix it... and learn how to not repeat it

I cut 3/4” plywood in three passes before and wouldn’t recommend doing it with any less. This was also done with a 3/8” bottom bearing bit so only 3/8” is being removed and the bit is not necked down between the router and the cutting edges increasing the chance of a broken bit when being overfeed. Precutting with a bandsaw or jigsaw and doing a final trim with a bit would greatly reduce not only the mess, but the strain put on the router and cutting bit.